Dixon 3000 Series Lawn Mower User Manual
Contents
1. IMPORTANT READ CAREFULLY The Dixon ZTR Mower is both easy and fun to operate However any power mower must be operated properly to be safe It is not a toy or a recreational vehicle Before you start to use the mower read the operator s manual carefully and become completely familiar with the controls The information in this operator s manual applies to all Dixon ZTR 4500 Series Model Mowers Your Dixon dealer will gladly provide a check out ride and answer any questions See your dealer for warranty service parts and repairs MIXO DIXON INDUSTRIES INC A BLOUNT International Inc Co PO BOX 1569 COFFEYVILLE KS 67337 0945 316251 2000 4500 Series Part No 5863 mn1 98 MY98 INDEX SAFETY aa a e E E Pages 1 6 WARRANTY POLICY Page A EE E ES ATE NE EEE E A 7 SPECIFICATIONS rsisi aaaea Page E EE E E E A E 8 E E E Raa orm ehcp 9 CONTROLS Pages 10 13 OPERATION INSTRUCTIONS Pages 14 19 CARE AND Pages 20 30 STANDARD 51185 Page 31 32 34 SAFETY RIDING LAWNMOWERS IF IMPROPERLY OPERATED CAN CAUSE SERIO2. Model 451 5K STARTING SYSTEM TIRES RECOMMENDED TIRE PRESSURE CAPACITIES DIMENSIONS NOTE SPECIFICATIONS Models ZTR 4515Band4515K Twin 12 gauge side frames and 7 gauge transmission and engine base plate All body parts are made of high density polyethylene Dent and corrosion resistant Front body contains access panel for battery service 36 Deck 1 1 GA Laser Cut Fabricated 36 Cut Width 42 Deck 13 GA Stamped Steel Construction 42 Cut Width Cut height approximately 1 to 4 via 7 position lift handle Electric clutch Each rear wheel is independently driven by a HydroGear IZT hydrostatic drive 15 HP Vanguard Briggs amp Stratton 4 Cycle Single Cylinder Overhead Valve Air Cooled Gasoline Vertical Shaft With Cast Iron Cylinder Sleeve Oil Pump With Integral Oil Filter 15 HP Kohler Command 15 4 Cycle Single Cylinder Overhead Valve Air Cooled Gasoline Pressure Lubricated With Oil Filter Vertical Shaft Aluminum Head and Block with Cast lron Cylinder Liner Electric by key switch operation with safety interlock blade drive Front 1 1X 4 00 X 5 ribbed tread Rear 18 X 8 50 X 8 Multi Trac Front 16 21 Ibs Rear 8 1 4 Ibs Fuel 2 7 gallons total Engine Briggs amp Stratton 1 50 quarts oil Kohler 2 quarts oil with filter Width 44 Maximum Track Width Height 42 to top edge of seat Length 72 hitch tab to front bumper Weight Power Unit 463 Ibs w 36 Deck 544 Ibs w
3. P N 1208310 Pre Cleaner P N 1208312 Engine Oil Filter P N 52 050 02 Page 31 TROUBLESHOOTING MOWER CUT QUALITY There are many variables that can effect the cut quality of any riding mower Type and conditions of grass cut height setting engine RPM and ground speed are some of the variables that interact creating differences in cut quality Examination of one or more of the above will generally produce a quality cut The Troubleshooting Chart suggests practices and adjustments that may be helpful in improving cut quality Your Dixon ZTR dealer is also available to provide assistance to you SITUATION Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Page 32 CAUSES Ground speed Incorrect engine to mower deck belt Engine RPM too low Dull or bent blade Un level mower deck Grass buildup under mower deck Improper blades Uneven tire pressures REMEDY Reduce mowing speed Refer to page 31 for part numbers Increase engine RPM to maximum Sharpen or replace as required Refer to page 25 for deck leveling procedure Clean out underside of mower deck Refer to page 31 for part numbers Refer to page 30 for correct tire pressures DRIVE SYSTEM SITUATION Mower creeps in neutral position Mower pulls to one side or the other Loss of power and speed on both sides Drive system functions
4. 42 Deck 541 Ibs Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Page 8 SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 4515B amp ZTR 4515K 1 Place parking brake in ON position Pull brake lever up 2 Raise and push seat assembly forward 3 Loosen five nuts P N 3205 and slide seat forward or backward to desired position Re tighten nuts P N 3205 DO NOT operate mower without seat adjustments properly tightened 4 Raise and push seat assembly and upper body rearward to closed position Page 9 CONTROLS Models ZTR 4515B and4515K CONTROL LEVERS FRONT OF MACHINE IGNITION SWITCH THROTTLE CONTROL Page 10 CONTROLS All controls are described from operators position PARKING BRAKE The parking brake used on the ZTR 4500 Series Models is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion The engine will stop if the parking brake is engaged while the control levers are in the drive position TO SET PARKING BRAKE The parking brake is located on the right fender of Models ZTR 4515B and ZTR 4515K To engage brake pull lever up and to the rear To release brake move lever forward and down NOTE Always set parking brake before dismounting Release parking brake before moving mower TRANSMISSION DRIVE SYSTEM Allows the
5. Never carry passengers Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing Be aware of the mower discharge direction and do not point it at anyone Do not operate the mower without either the entire grass catcher or the deflector in place Slow down before turning e Never leave a running mower unattended Always turn off blades set parking brake stop engine and remove key before dismounting Turn off blades when not mowing e Stop engine before removing grass catcher unclogging chute Mow only in daylight or good artificial light Do not operate the mower while under the influence of alcohol or drugs e Watch for traffic when operating near or crossing roadways e Use extra care when loading or unloading the mower into a trailer or truck Do not ride the mower when loading amp unloading The Engine Exhaust from this product contains chemicals known to the A WARN N G State of California to cause cancer birth defects or other reproductive harm Page 3 SAFETY SLOPE OPERATION DO Slopes are a major factor related to loss of control and tip over accidents which can result in severe injury or death All slopes require extra caution If you cannot back up the slope or if you feel uneasy on it do not mow it Mow across the slope with your Dixon ZTR never up or down Remove obstacles such as rocks tree limbs etc Watch f
6. be sure it is in place 5 Be sure parking brake is on 6 Be sure mower blade drive is off 7 Know how to stop engine Turn key to off position Page 14 OPERATION INSTRUCTIONS SAFETY SYSTEMS PARKING BRAKE SWITCH TEST CONTROL LEVER SWITCH TEST BLADE DRIVE SWITCH TEST SEAT SWITCH TEST Swing out control levers Disengage blade drive switch Put Parking brake in OFF position Turn ignition switch to START Engine should not turn over or attempt to ctart a Disengage blade drive switch b Put parking brake in ON position Swing control levers in Turn ignition switch to START Engine should not turn over or attempt to c d start a Put parking brake in ON position b Swing out control levers c Engage blade drive switch d Turn ignition switch to START Engine should not turn over or attempt to start a In a SAFE AREA away from bystanders start the engine b Leave levers swung out and parking brake ON c Engage blade drive d Raise weight slightly off seat ENGINE SHOULD STOP e Disengage blade drive f with engine running put parking brake in OFF position g Swing levers in h Engage blade drive i Raise weight slightly off seat ENGINE SHOULD STOP NOTE If Any Safety Check FAILS Do Not Operate The Mower until the system has been checked and repaired by an Authorized Dixon ZTR Dealer Page 15 OPERATION INSTRUCTIONS The Dixon ZTR requires only two
7. drive levers to control braking turning speed and direction On initial operation set throttle speed on slow amp operate with mower blade OFF To avoid over controlling the mower use a light touch on the drive levers Slight movements using fingertip control is all that is necessary A CAUTION Engage parking brake before starting engine STARTING INSTRUCTIONS 1 Parking brake must be on control levers swung out and blade drive disengaged 2 Move throttle control to Choke position if engine is cold full throttle if warm Insert ignition key and turn to Start position When engine starts release ignition key Key will return to Run position 4 Move throttle from Choke to desired speed position 5 Release parking brake CHOKE RUN 6 Swing levers in FAST NOTE While mowing throttle control should be set to the MAXIMUM or wide open setting to insure adequate IGNITION cooling of the engine and to maintain mower deck blade speed Engine cannot be restarted when blade drive is engaged the parking brake is off or levers are swung THROTTLE In OFF 1 Safety switches stop engine when operator leaves seat ED BLADE DRIVE while mower blade is engaged OFF Always turn engine off when leaving mower DO NOT O LIGHTS 5 2 O rely on safety switches Page 16 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT Mulching or recyclin
8. on one side only CAUSES Neutral adjustment Forward travel speed adjustment Incorrect or worn drive belt Spring on idler arm missing or broken Idler arm will not pivot Internal malfunction Incorrect or worn drive belt Spring on idler arm missing or broken Idler arm will not pivot Internal malfunction REMEDY Refer to page 24 for procedure or consult your dealer for repair Refer to page 23 for procedure Replace belt Replace spring Remove cause of seizure and lubricate Consult your dealer for repairs Replace belt Replace spring Remove cause of seizure and lubricate Consult you dealer for repairs TROUBLESHOOTING ELECTRICAL SYSTEM SITUATION Starter will not turn engine over Starter will not turn engine over Battery discharge Battery discharge Battery discharge CAUSES Circuit breaker disengaged Dead battery Poor connections on battery Battery water low Wrong battery installed in mower Engine electrical system not functioning correctly Engine not being operated at full throttle REMEDY Push button to reset Consult your dealer for repair Charge battery Tighten or replace as required Have electrical system checked by your dealer increase engine RPM Contact your dealer for information NOTE Electrical system failures are generally simple in nature always check the obvious first and then move onto the more complicated parts used Poor batte
9. 1 Raise the height of cut setting on your mower 2 It may be necessary to cut your grass more frequently 3 Operate the mower at a slower ground speed 4 Overlap cutting swaths instead of cutting a full swath with each pass 5 Mow across the marginal areas a second time 6 CUT HIGH MOW OFTEN Page 17 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT In order to achieve optimum performance when mowing with a grass catching attachment please read and follow the tips listed below 1 Some applications may require installation of an Optional weight box on the front of the mower to offset cut grass weight 2 Set engine speed control to the wide open or full setting 3 Do Not Attempt Cut Grass When It Is Wet Wet grass will clog both the underside of the deck and the attachment chutes Empty bags often to prevent plugging 4 Ifthe grass is tall place the mower deck cut height selector the top or second notch Initially overlap cutting swaths instead of a full swath with each pass 5 Keep The Underside Of The Mower Deck Clean Frequent removal of dried grass and dirt will greatly assist in bagging of the clippings 6 Maintain Sharp Blades Throughout The Cutting Season Some grass catching attachments require Hi Lift blades 7 Operate the mower at a slower ground speed than when mowing without a grass catching attachment 4 CAUTION Watch for low hanging branches or other obs
10. AINTENANCE NEUTRAL ADJUSTMENT DRIVE MACHINE UNTIL HYDROSTATS HAVE WARMED UP WITH ENGINE RUNNING AND THE PARKING BRAKE OFF SWING OUT THE CONTROL LEVERS IF MACHINE STARTS TO CREEP FOLLOW THE INSTRUCTIONS BELOW 1 Stop the engine engage parking brake and raise rear of frame with jack or blocks so that rear tires do not contact the ground 2 Swing out the control levers start the engine and release the parking brake 3 Raise the seat to access hydro control linkage If right wheel creeps adjust right side linkage and vice versa Use procedure below a Loosen but do not remove the bolt in the control tube P N 5540 b Loosen Jam nuts on ends of the PAMEN IN STEP coupler P N 7736 TIGHTEN IN STEP D 7736 COUPLER ADJUST IN STEP C If right wheel is creeping forward turn coupler counter clockwise until neutral is achieved clockwise for left side If right 7585805 wheel is creeping backward tum TIGHTEN IN STEP coupler clockwise until neutral is achieved counterclockwise for left side d Tighten jam nutsagainst coupler e Tighten bolt in control tube 4 Lower seat release parking brake and swing control levers in If wheel creeps repeat steps 3a amp 3e 5 Stop engine and remove rear of machine from jack or blocks ONTROL LEVER MOUNTING NUT LOOSEN NUT AND ROTATE LEVER IF NECESSARY 6 Drive machine with both levers in top speed position If one side now drives CONTR
11. OL slightly faster than the other adjust lever stop washer P N 5760 on that side to reduce forward range of control lever If levers are now uneven at top speed loosen control lever mounting nut Rotate lever to be even with other side and tighten nut 5760 LEVER STOP WASHER ADJUST POSITION TO CHANGE FORWARD RANGE OF CONTROL LEVER IF NECESSARY Page 24 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE 1 Place mower a smooth level surface and check tire pressures to insure correct stance Tires should be inflated as follows Front 16 21 Ibs Rear 8 14 lbs 2 Turn each outer blade tip to align with the deck in a side to side manner 3 Measure from the floor surface up to the bottom of the blade tip on the discharge side of the mower Retain this measurement Move to the opposite side and check to see if that measurement is the same f adjustment is required tum nut on one or both of the rear L rods until both measurements are equal 4 Turn each outer blade tip to align with the deck in a front to rear manner 5 Measure from the floor surface up to the bottom of the blade tips at both the front and rear of the blades Rear of blade tips should be level to 1 4 higher that the front of blade tips If adjustment is necessary turn nut on front L rod NOTE This will place the mower deck in a base measurement position Additional adjustment may be required to achieve desired cut for the type of grass or cond
12. US INJURY OR DEATH The most common causes of injury to the operator or bystander BLADE CONTACT RUN OVER TIP OVER RUN OVER read and understand this manual to prevent injuries Page 1 Ad SAFETY SAFETY SYMBOLS A CAUTION SAFETY ALERT SYMBOL When you see this symbol BE ALERT to the potential for injury Follow recommended safety precautions and safe operating practices Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Page 2 SAFETY This cutting mower is capable of amputating hands and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death GENERAL OPERATION e Read understand and follow all instructions in the manual on the mower before starting Only allow responsible adults who are familiar with the instructions to operate the mower e Clear the area of objects such as rocks toys wire etc which could be picked up and thrown by the blade e Be sure the area is clear of other people before mowing Stop mower if anyone enters the area e
13. g loaded idler system A pulsing movement of the belt idler will be observed both during engagement of the electric blade clutch and actual operation of the mower deck NOTE Engagement of the electric blade clutch switch may H sce a sharp high pitched chirp or squeal as the belt tension loading ir v rbed by the idler system This is normal and not a sign of failure 36 DECK MOWER DECK DRIVE BELT P N 1300 42 DECK MOWER DECK SERPENTINE BELT P N 6109 Adjustment procedure illustration below for 36 Mower Deck Drive Beit P N 1300 and 42 Mower deck Serpentine Belt P N 6109 DLER IDLER WELDMENT SHOCK LAJ 36 DECK DRIVE Bere TIGHTEN OR LOOSEN HEX ACHIEV 42 DIMENSIONS SHOWN Page 22 CARE AND MAINTENANCE FORWARD TRAVEL SPEED ADJUSTMENT 1 Drive machine until hydrostats have warmed up 2 Drive smooth level surface with both levers top speed position 3 If one side now drives slightly faster than the other adjust lever stop washer P N 5760 on that side to reduce forward range of control lever If levers are now uneven at top speed loosen control lever mounting nut Rotate lever to be even with other side and tighten nut CONTROL LEVER MOUNTING NUT LOOSEN NUT AND ROTATE LEVER IF NECESSARY CONTROL LEVER O LEVER STOP WASHER ADJUST POSITION TO CHANGE FORWARD RANGE OF CONTROL LEVER IF NECESSARY Page 23 CARE AND M
14. g the grass clippings requires a totally different mowing approach than would be normal when side discharging or bagging the grass There may be instances or conditions where it is not possible to hide all of the recycled or mulched clippings In order to achieve the best results please read and follow the mulching tips listed below 1 Set the engine speed control to the wide open or full setting 2 the mower deck cut height selector in either the top or second notch Never cut more than 3 4 to 1 off the grass at any one time Attempting to cut more grass will result in the deck plugging and cause the engine to stall 3 It may be necessary to cut the lawn twice to achieve acceptable mulching performance especially on first cuttings or if the lawn is heavily fertilized 4 Do Not Attempt To Cut Grass When It Is Wet Mulching performance will be very poor under wet grass conditions 5 Maintain A Sharp Blade Throughout The Cutting Season This is very important Optimal mulching performance cannot be obtained with a dull or nicked up blade 6 Keep The Underside Of The Mower Deck Clean Remove all grass and dirt buildup from the underside of the pan the baffles and deflectors after each use 7 Alternate mower direction This will evenly disperse the mulched grass clippings over the lawn for even fertilization If the mulching quality of the mower does not seem to be satisfactory try one or more of the following tips
15. ht To engage the mower blades move switch to the rear and lift To disengage blades move switch backward Switch is clearly marked on and off CIRCUIT BREAKER Protection of the electrical system is by 1 15 amp circuit breaker If circuit breaker trips push button to reset If this condition repeats consult dealer for inspection and repair MOWER DECK CUT HEIGHT LIFT LEVER Located to the left of operator Controls the cutting height Seven positions of adjustment Move lever in and forward to lower Move lever in and back to raise NOTE Always use high for transport DIXON ZIR CHOKE OFF FAST IGNITION THROTTLE ON OFF ia BLADE DRIVE OFF 5 E 13 OPERATION INSTRUCTIONS The safe and successful operation of the ZTR 4500 Series Models will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed NEVER allow anyone to operate the mower without complete knowledge of all controls and their functions During initial operation learning to drive set throttle at slow speed Sound judgement by the owner will prevent accidents BEFORE OPERATING MOWER 1 Read engine manufacturer s operating and maintenance instructions 2 Read and observe all safety instructions on your mower and in the manual 3 Check engine oil 4 Check gas cap to
16. ies contain sulfuric acid To prevent burns avoid contact with skin eyes and clothing To prevent a fire or explosion keep sparks and open flames away from battery Before disconnecting the negative ground cable make sure all switches are OFF Page 6 DIXON PROTECTION PLUS TWO YEAR LIMITED WARRANTY POLICY This warranty policy applies to all ZTR 4500 Series mowers purchased on or after September 1 1997 WARRANTY The Dixon Protection Plus Warranty term is for a period of two 2 years from date of purchase DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS 1 Warranty applies only to original retail purchaser of new and unused mowers and accessories 2 All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty policy and allowances All warranty claims must be approved by Dixon Industries Inc 3 Mowers or accessories used for commercial applications are warranted for 90 days from date of purchase Commercial application is any use other than or in addition to mowing at owner s primary place of residence 4 Battery warranty Limited to 90 days from date of purchase 5 Accessories Warranty Grass Catchers Snow Blades Covers etc Limited to 90 days from date of purchase 6 Warranty does not apply to damage in trans
17. ire replacement of the oil filters These filters can be obtained from your authorized engine dealer The use of any other oil filter may cause damage to the engine Model ZTR 4515B Model ZTR 4515K Briggs amp Stratton Oil Filter P N 492 932 Kohler Oil Filter P N 52 050 02 PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS PROTECT YOUR ENVIRONMENT LUBRICATION CHASSIS LOCATIONS Number of grease zerks used 4 SERVICE INTERVALS 1 each front wheel caster tube and each front wheel hub RECOMMENDED GREASE Every 50 hours of operation Name brand wheel bearing or multi purpose grease GREASE Lubricate each front wheel to allow even distribution of grease ZERK within the wheel rotate or spin each front wheel after 3 pumps of the grease gun Repeat process until the appearance of grease is noted completely around each caster axle GREASE ZERK Page 29 WHEELS AND TIRES ELECTRICAL SYSTEMS CLEANING THE MOWER SERIAL NUMBERS WARRANTY PARTS SERVICE CARE AND MAINTENANCE Correct tire pressure is important for correct operation of mower Front Tires 11X4 00X5 Air Pressure 16 21 Ibs Rear Tires 18X8 50X8 Air Pressure 8 1 4 Ibs NOTE Check lug nuts periodically for tightness Keep all connections clean and tight Wash mower periodically Clean above and below deck NOTE Allow mower to coo before washing If bearings are hot they will draw moisture inside as they dry and cause corrosion The
18. it or incidents of misuse negligence accidents or alteration The use of parts or components other than those supplied by Dixon Industries Inc VOIDS ALL WARRANTY 7 The following items are not covered by this warranty policy a Pick up and delivery charges for transportation of mower to and from an Authorized Dixon Dealer s place of business b Routine maintenance or adjustments Belts chains sprockets cutting blades d Engines All engines used on Dixon ZTR mowers are warranted by each individual engine manufacturer e Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower 8 There is no other express warranty Implied warranties including those of merchantability and fitness for a particular purpose are limited to the same duration of the express warranty and to the extent permitted by law any and all implied warranties are excluded Liabilities for consequential damages under any and all warranties are excluded WARRANTY VALIDATION At the time of sale selling dealer must review each portion of this warranty document complete the information section below secure customer s signature and send copy to Dixon Industries Inc DATE OF PURCHASE Model S N DM Owner s Name Dealership Address Address Owner s Signature Dealer s Signature Page 7 CHASSIS BODY MOWER DECKS BLADE DRIVE TRANSMISSION ENGINE Model 451 5B
19. itions involved REAR L RODS TURN NUT S ADJUST SIDE TO SIDE MEASUREMENT FRONT L ROD TURN NUT TO ADJUST FRONT TO REAR MEASUREMENT Page 25 CARE AND MAINTENANCE 36 DECK REMOVAL 1 Place cut height lever in lowest cut position 2 Loosen nut on belt idler shock mount until belt can be removed from electric clutch pulley on the bottom of the engine 3 Remove hair pin cotter and washer from one end of deck support cross shaft Note location of remaining shim washers used between chassis and mower deck plates Slide shaft from chassis and mower deck 4 Remove hair pin cotter and washer from each deck L rod Remove L rods from lift arms At this point deck will drop down 5 Carefully raise and support front of chassis Slide mower deck to either side for removal Reverse procedure to reinstall deck assembly LOOSEN NUT TO RELIEVE BELT TENSION FOR REMOVAL OF DECK DRIVE BELT COTTER PIN Page 26 CARE AND MAINTENANCE 42 DECK REMOVAL 1 Place cut height lever in lowest cut position 2 Pull belt idler back to allow belt to be removed from idler pulley and electric clutch pulley 3 Remove hair pin cotter and washer from one end of deck support cross shaft Note location of remaining shim washers used between chassis and mower deck plates Slide shaft from chassis and mower deck 4 Remove hair pin cotter and washer from each deck L rod Remove L rods from lift arms At this point deck wi
20. ll drop down 5 Carefully raise and support front of chassis Slide mower deck to either side for removal Reverse procedure to reinstall deck assembly NOTE When deck is reinstalled on frame check that belt is correctly routed in the groves of all pulleys and that belt idler is applying tension to the back side of the belt ROTATE IDLER TO RELIEVE BELT TENSION FOR REMOVAL OF DECK DRIVE BELT COTTER PIN oF WASHER WASHER WASHER COTTER PIN Page 27 CARE AND MAINTENANCE A CAUTION HOT oil may cause burns Allow engine to cool before draining oil CHANGING THE ENGINE OIL 1 The snap lock oil drain valve is located on the left side of the engine crankcase 2 Place a suitable container under the drain valve The fitting of a short piece of hose to the valve will help direct the oil 3 Push the valve body in and twist o clear the detent notch 4 Pulling the valve body outward will start the flow of oil NOTE Refer to engine manufacturers recommendations for frequency of oil changes MODEL 4515K Page 28 PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS PROTECT YOUR ENVIRONMENT CARE AND MAINTENANCE OIL FILL 1 Push the valve body in and twist into the detent NOEN Closed Open 2 Clean any spilled oil from engine and chassis 3 Refill engine with type and quantity of oil recommended by the engine manufacturer in engine literature NOTE Oil changes requ
21. mower to turn on its own axis Zero Turning Radius Each lever controls one side of the mower NOTE The pressure required to operate the mower is very light Page 11 A minimum of 1 2 hour should be spent simply driving the mower without the blade drive engaged CONTROLS NEUTRAL SLOW FAST 90 SLOW FORWARD FORWARD RICHT REVERSE TO GO FORWARD From neutral position gently push both drive levers forward To increase speed move levers farther forward TO GO BACKWARD From neutral position gently pull both drive levers toward you TURNING Turning is controlled by moving one drive lever slightly forward or rearward of the other To turn left move left lever rearward of the right lever To turn square corners move lever of desired direction to neutral To turn on mower s own axis zero turning radius stop and move one lever to reverse position and the other to forward position BRAKING To brake mower move both levers in direction opposite of travel release levers to neutral set parking brake Park only on level surfaces TWIN FUNCTION THROTTLE CONTROL Located on control panel to operator s right Throttle control for engine speed Choking for engine starting Throttle Control should be set to the MAXIMUM or wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed while mowing Page 12 CONTROLS BLADE DRIVE Located on control panel on operator s rig
22. or holes ruts or bumps Uneven terrain could overturn the mower Tall grass can hide obstacles Use slow speed Use extra care with grass catchers or other attachments These can change the stability of the mower Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction Avoid starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly down the slope DO NOT Do not turn on slopes unless necessary and then turn slowly and gradually downhill if possible Do not mow near drop offs ditches or embankments The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in Do not mow on wet grass Reduced traction could cause sliding Do not try to stabilize the mower by putting your foot on the ground Do not use grass catcher on steep slopes Page 4 SAFETY CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are attracted to lawn mowers and the mowing activity NEVER assume children will stay where they were last seen Keep children out of the mowing area and under the watchful care of another responsible adult Be alert and turn mower off if a child enters the area Before and during backing look behind and DOWN for small children e Never carry children They fall off and be seriously injured or interfere with safe mo
23. pressures Tightness of all nuts and bolts Battery fluid level Engine Oil OnkWNnN gt A CAUTION _ Before performing any maintenance shut off engine allowto cool ENGINE For engine operating and maintenance information refer to the engine operating and maintenance instructions furnished by the engine manufacturer supplied with each mower BATTERY Check the fluid in the battery at frequent intervals Keep fluid level above the plates in each cell using distilled water OFF SEASON BATTERY STORAGE Identify each cable so cables can be reconnected to correct terminals Disconnect cables from terminals ALWAYS disconnect ground cable first and reconnect last Charge battery DO NOT remove battery from mower Clean top of battery and terminals with baking soda and water Page 20 CARE AND MAINTENANCE MOWER BLADE MAINTENANCE NOTE Observe proper blade position prior to removal 1 Safely raise front of mower 2 Hold or block blade from turning 3 Loosen blade nut and remove blade A CAUTION Wear heavy thick gloves when holding onto mower blade avoid the sharp edge of the blade 4 Tighten blade nut securely Refer to diagram THREADED END OF BLADE SHAFT TRASH GUARD MOWER BLADE 7 21 CARE AND MAINTENANCE BELT TENSION 42 DECK ENGINE TO MOWER DECK BELT P N 5861 No adjustment required Correct belt tension is maintained through a fixed engine location and a sprin
24. ry service loose connections corrosion frayed or broken wiring are more likely than component failure Page 34 DIXON INFO RMATION DIXON INDUSTRIES INC A BLOUNT International Inc Co PO BOX 1569 COFFEYVILLE KS 67337 0945 316251 2000 FAX 316 251 4117 DATE PURCHASED MOWER MODEL NUMBER MOWER SERIAL NUMBER DM PURCHASED FROM Name Address DATE OIL CHANGED DATE ENGINE TUNED DIXO ZTR Mowers A WARN NG The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Dixon and ZTR are registered trademarks of Dixon Industries Inc DIXON INDUSTRIES INC 4500 Series A BLOUNT International Inc Co Part No 5863 PO BOX 1569 MY98 mn1 98 COFFEYVILLE KS 67337 0945 316251 2000
25. serial number is located on frame at rear of engine it will begin with DM Refer to Warranty Registration Form P N 5859 See your Dixon dealer for replacement parts warranty or service PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND Page 30 ANIMALS IN YOUR AREA STANDARD SERVICE PARTS LIST 36 DECK BLADES Standard P N 1324 Hi Lift P N 1351 Right Side P N 1352 LeftSide BELTS Engine To Mower Deck P N 1300 Engine To Transmission P N 5768 42 DECK BLADES Standard Hi Lift P N 8688 Lo Lift P N 6236 BELTS Engine To Mower Deck P N 5861 Serpentine Belt P N 6109 Engine To Transmission P N 5768 BRIGGS amp STRATTON FILTER PART NUMBERS Please refer to Briggs amp Stratton Engine Operators Manual for correct service intervals for engine oil changes and air filter maintenance Protect your engine investment use only original equipment filters Model ZTR 451 5B 15HP Precleaner Foam Element P N 272403 Model ZTR Air Filter Cartridge P N 493 909 45158 15HP Engine Oil Filter P N 492 932 Precleaner Foam Element Air Filter Cartridge P N 493 909 Engine Oil Filter P N 492 932 KOHLER FILTER PART NUMBERS Please refer to Kohler Engine Operators Manual for correct service intervals for engine oil changes and air filter maintenance Protect your engine investment use only original equipment filters Model ZTR 451 5K 15 Air Filter Cartridge
26. tacles which might hit the catcher top while turning or backing the mower e Use care when backing to avoid pushing the grass bags into the frame or hot exhaust muffler of the engine Disengage blade and stop engine prior to clearing grass from either the discharge chute or grass catcher components e Keep all attachment bolts tight Do Not operate the mower with the grass catching attachment partially removed Important Do not leave clippings in the bags while the mower is stored Damp grass clippings are a fire hazard if left in the bags Lo anaa a ae Ti RSE CN Ee et eel Page 18 OPERATION INSTRUCTIONS SIDE DISCHARGE OF THE CLIPPINGS In order to achieve optimum performance when side discharging the grass clippings please read and follow the tips listed below Additional information can be found in the troubleshooting guide A CAUTION Be sure that deflector is properly installed on the discharge chute 1 Set engine speed control to the wide open or full setting 2 Do Not Attempt Cut Grass When It ls Wet Wet grass will clog the underside of the deck and discharge area 3 If the grass is tall place the mower deck cut height lever in the top or second notch Initially overlap cutting swaths instead of a full swath with each pass Some applications may require a second cutting 4 Keep The Underside Of The Mower Deck Clean Frequent removal of dried grass and dirt will allow the clippings
27. to discharge correctly 5 Maintain Sharp Blades Throughout The Cutting Season GRASS HEIGHT SUGGESTIONS Correct mowing height can reduce weeds and disease by 50 to 80 The following grass cut heights are based on adequate moisture conditions and normal thatch buildup in a healthy lawn Some locations and applications may require slightly different cut heights If in doubt consult your local lawn professional for assistance Grass Types Best Cut Heights Zoysia 2 2 1 2 Blue Grass 1 1 2 3 Fescue Blends 1 1 2 3 St Augustine Mid South St Augustine Deep South 3 4 Tifton Bermuda 1 1 2 Centipede 1 1 2 2 Common Bermuda 1 1 2 2 Bahia Argentina Pensacola 19 CARE AND MAINTENANCE This portion of the ZTR 4500 Series Models owners manual deals with normal service items which can be performed by the owner Please remember that if you are in doubt as to the correct service procedures to be followed these and other service situations can be handled by a Dixon ZTR dealer who is familiar with the service of your mower MAINTENANCE SCHEDULE To insure a long and trouble free service life on all the components used on the ZTR 4500 Series Models a regular and thorough maintenance schedule should be followed The following items should be checked after the first 10 hours of operation and on a weekly basis or each 40 hours of use Drive system belts and controls Mower deck belts Tire
28. wer operation e Never allow children to operate the mower e Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision Page 5 SAFETY SERVICE e Use extra care in handling gasoline and other fuels They are flammable and vapors explosive Do not smoke e Use only an approved container e Never remove gas cap or add fuel with the engine running Allow engine to cool before refueling e Never refuel the mower indoors e Never store the mower or fuel container inside a building where there is an open flame e Never run a mower inside a closed area e Keep nuts bolts especially blade attachment bolts tight and keep equipment in good condition e Never tamper with safety devices Check their proper operation regularly e Keep mower free of grass leaves or other debris buildup Clean up oil or fuel spillage Allow mower to cool before storing e Stop and inspect the equipment if you strike an object Repair if necessary before restarting e Never make adjustments or repairs with the engine running e catcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with original equipment parts when necessary e Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them e Batter
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